Corrosion is more than cosmetic damage; it is an economic and operational threat that ticks away every hour a heat exchanger is in service. In shell-and-tube units—the workhorses of refineries, chemical plants, and power stations—even a hair-thin layer of corrosion product can drop overall heat-transfer efficiency and set the stage for leaks, unplanned shutdowns, and safety incidents.

Why does this resonate with our clients? Because every megawatt of lost heat-duty or every unscheduled maintenance window erodes margins and can jeopardize delivery commitments. In an environment where stakeholders demand lower carbon intensity and higher reliability, corrosion-driven fouling is a silent cost driver few operators can afford to ignore.

Cortec Global Services Engineering & Technical Sales Director, James Holden recently unpacked these challenges in Heat Exchanger World magazine, spotlighting three key takeaways:

• Common corrosion types affecting heat exchangers

• How they reduce efficiency and reliability

• What to do — from smarter design to proactive protection

Read the full article from Heat Exchanger World (click on link) or contact our Houston office at info@cortecgs.com to schedule a corrosion strategy session tailored to your heat-exchange assets.

James (Jim) E. Holden, PE has a professional engineer license, a bachelor’s degree in mechanical engineering, a master’s degree in Business, and a Master Black Belt certification in Six Sigma Quality. Jim has 40 years of experience working directly in the energy field, including tours at GE, Dresser-Rand, Alstom Steam Turbine, and Westinghouse. He spent 11 years at Cortec® addressing corrosion related issues and is now helping clients translate insight into action at CGS – U.S.

At CGS, our field teams audit metallurgy, operating parameters, and water chemistry to pinpoint root causes, then engineer a program that can include film-forming VpCI® inhibitors, high-performing VpCI® coatings, and other measures. Clients who adopt our recommendations often report double-digit reductions in maintenance spend and downtime, helping them hit production and ESG targets simultaneously.

The bottom line: corrosion is inevitable, but its impact is not. By integrating smarter design, data-driven inspection plans, and proven preservation technologies, owners can extend exchanger life, cut energy use, and avoid the domino effect of unexpected failures.